Washington University in St.

Louis
Washington University Open Scholarship
Mechanical Engineering and Materials Science
Mechanical Engineering & Materials Science
Independent Study

5-12-2016

Processing and Properties of Metal Matrix

Composites
Son N. Trinh
Washington University in St Louis

Shankar Sastry
Washington University in St. Louis

Follow this and additional works at: https://openscholarship.wustl.edu/mems500

Recommended Citation
Trinh, Son N. and Sastry, Shankar, "Processing and Properties of Metal Matrix Composites" (2016). Mechanical Engineering and
Materials Science Independent Study. 10.
https://openscholarship.wustl.edu/mems500/10

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 1

PROCESSING AND PROPERTIES

OF
METAL MATRIX COMPOSITES

Son Trinh
Department of Mechanical Engineering and Materials Science
Washington University in St. Louis, St. Louis, MO

MEMS 400 - Independent Study in partial fulfillment of Bachelor’s Degree in Mechanical

Engineering
Spring Semester 2016.

Faculty Advisor: Prof. Shankar Sastry

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ABSTRACT

The study was conducted to investigate the general properties and processing methods of
metal matrix composites in comparison with polymer matrix composites and ceramic matrix
composites. In addition, the properties of the most widely used metal matrix composites
(aluminum and magnesium) were also studied. The information was collected from published
online articles and journals on metal matrix composites. While metal matrix composites have
been widely used in the aerospace and automobile industry, their properties are still being
researched for further development and applications.
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I. INTRODUCTION & BACKGROUND

Composites consist of two or more physically and/or chemically distinct materials. There are
three components of a composite: matrix, reinforcement, and the interface between matrix and
reinforcement. A matrix is a continuous phase of composites and serves to hold the
reinforcements in predetermined orientation. A reinforcement is a stronger material distributed
within the matrix. Matrix and reinforcements are chemically bonded or mechanically locked
together. Matrix, reinforcements, and the interface determine the characteristics of a composite.
While the characteristics of a matrix material are changed in the composite making process,
those of reinforcing materials remain the same except in rare instances of processing at very high
temperature.

Composites are classified based on the types of matrix and reinforcements. Composites are
classified as polymer matrix composites (PMCs), metal matrix composites (MMCs), and
ceramics matrix composites (CMCs) based on the type of matrix. Depending on the types of
reinforcements, composites include particle reinforced composites, short fiber composites
(whisker), and continuous fiber composites (sheet). The materials for reinforcements can be
organic fibers, metallic fibers, ceramic fibers, and particles. The materials for matrices can be
polymers, metal and its alloys, glasses, glass-ceramics, ceramics. Usually, the strength of a
matrix is considerably less than that of a fiber reinforcement [1].

In PMCs, matrices are mostly cross-linked thermoset polymers (epoxy, polyester, phenolics).
Glass fiber-reinforced thermoset polymers have high strength and stiffness to weight ratio, thus
they are usually used in automotive components. Other matrices in PMCs include thermoplastic
resins (PE, Nylon, PVC, …) [1]. In MMCs, light metals like aluminum, titanium and
magnesium, and their alloys are usually used as matrices. Aluminum is most commonly used due
to its excellent strength, toughness, and resistance to corrosion and abrasion [2]. In CMCs,
silicon carbides are regularly used for both matrices and reinforcements. However, the silicon
carbide reinforcements are of multiple forms to achieve preferred properties [5].

In particle reinforced composites, particles can be ceramics, glasses, metal, and/or

amorphous materials. While the modulus of a composite is higher than that of its matrix, the
permeability and ductility are lower. Therefore, particle reinforced composites can sustain higher
 4

tensile, compressive and shear stresses. Fiber reinforced composites consist of short fiber
composites and continuous fiber composites. The modulus of a composite of this type is higher
than that of a matrix because of the strong covalent bonds along the fiber length. The orientation
of the fibers relative to one another has significant impact on the mechanical properties of the
composite.

In addition to matrix and reinforcements, the interfaces also play an important role in the
properties of composites. As matrix and reinforcements are not in thermodynamic equilibrium at
the interface, a discontinuity of one or more material parameters (elastic moduli, strength, and
chemical potential) occurs. The interfaces create a medium for the transitions and avoid a jump
in material parameters between matrix and reinforcements: the transitions gradually take place
over the thickness of the interface [3]. In addition, there is a chemical compound formed from
the matrix materials and reinforcing materials at the interface due to the discontinuity in
chemical potential. This chemical compound forms an interaction zone of which a certain
thickness is desirable as long as it does not affect the properties of a composite. The
discontinuity in thermal expansion coefficient of matrix and reinforcements can lead to thermal
stresses in the interfacial regions of composites. Under extreme conditions, the thermal stresses
result in plastic deformation in a metallic matrix and cracking in a brittle ceramic or polymeric
matrix, thus changing the matrix and composite characteristics. As the reinforcement diameters
decrease, the area of the interfacial regions increase, creating more medium for the chemical and
mechanical interactions between matrix materials and reinforcing materials and becoming more
important in governing the ultimate properties of a composite [3].

The interfacial bonding is always present between the matric and the reinforcements.
However, the bonding is not the same for all types of composites. Since high stiffness and load
bearing capacity are needed in PMCs and MMCs, strong bonding is usually chosen. On the other
hand, weak bonding is desired in CMCs in order to deflect cracking or bridge cracking by fibers,
thus increasing the toughness of the composites. The nature of bonding can be affected by
multiple factors including thermal, structural, chemical, mechanical (and wettability for a liquid
used in the manufacturing of the composite. In addition, the surfaces of fibers are often treated to
enhance mechanical and/or chemical bonding to a desirable degree [1].
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Important properties of composites are density, heat capacity, elastic moduli, strength, aging
kinetics, and toughness. Rules of mixtures (ROM) calculations are used to estimate the final
properties of a composite from its matrix and reinforcements. However, the behavior of
composites does not always follow the ROM calculations and ROM calculations are generally
valid only for continuous fiber reinforcements.
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II. PROCESSING OF METAL MATRIX COMPOSITES

Processing of metal matrix composites (MMC) can be classified into three main categories:

- Solid State Processing

- Liquid State Processing
- In-Situ Processing
Processing
Methods

Solid State Liquid State In-Situ

Processing Processing Processing

Power Blending
and Stir Casting
Consolidation

Diffusion
Squeeze Casting
Bonding

Physical Vapor
Infiltration
Deposition

Spray
Deposition

1. Solid State Processing

The main fabrication methods for solid state processing of metal matrix composites are
powder blending and consolidation, and physical vapor deposition.

a) Powder Blending and Consolidation:

Metal alloy powder is blended with ceramic whisker/short fiber/particles in dry condition
or in liquid suspension. After blending, the mixture is further processed by cold compaction,
canning, degassing, and high temperature consolidation. There are some oxide particles in
volume fraction of 0.05-0.5 depending on the powder and processing conditions that help
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dispersion-strengthening of the metal matrix composites [9]. This method is usually used for
the processing of aluminum and magnesium metal matrix composites.

b) Diffusion Bonding:

The inter diffusion atoms at the metallic surfaces under pressure creates bonding between
the metal matrix and fibers [14]. This fabrication method is widely used for aluminum or
magnesium MMCs reinforced with continuous/discontinuous fibers.

c) Physical Vapor Deposition:

Fibers are continuously passed through a region of high partial pressure of metal to be
deposited. The vapor is produced and inserted in the process, then the condensation occurs at
this region to produce a coating on the fiber. The rate of deposition is about 5-10 micrometer
per minute[14]. The coated fibers are then consolidated by hot pressing or hot isostatic
pressing [9].

2. Liquid State Processing

a) Stir Casting:

Particulate reinforcements are mixed with liquid metal melt and the mixture then
solidifies. Specifically, the pre-treated particles are inserted into the vortex of molten alloy,
which is created by a rotating impeller. A problem arises during the stir casting process as the
reinforcements are not uniformly distributed and form sediments in the molten alloy.
Generally, up to 30% particles in the size of 5-100 micrometer can be incorporated into the
metal alloy [9]. An example of this method is Al-(10-15%) B4C MMCs.

In another variant of the stir casting method, particles are introduced into the metal alloy
in the semi-solid state [9].

b) Squeeze Casting

Molten metal is introduced into an open die. The dies are then closed so that the molten
metal solidifies under pressure within the dies. The heat is rapidly transferred from the
molten metal to the dies under high pressure and through the contact between the metal and
the die surface. As a result, a fine-grain casting with little to no pore is produced using this
method [8][9][15].
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c) Infiltration Process:

Liquid metal alloy is infiltrated into the porous forms of fibers/whiskers reinforcements.
The volume fraction of the reinforcements usually ranges from 10-70%, depending on the
level of porosity. Silica and metal-based mixtures are often employed as binder to retain the
integrity and shape of the porous forms [9].

d) Spray Deposition

Particle/whisker/short fiber reinforcements are injected into the spray, creating a

deposition layer of porosity of 5-10% on the metal surface. The depositions are then
consolidated to full density by further processing [9].

For continuous (long) fiber reinforced metal matrix composites, matrix metals are
sprayed onto the fibers. The fiber spacing and fiber layer in this processing method impact
the fiber volume fraction and distribution [9].

3. In-Situ Processing

In-situ processing involves chemical reactions that result in the creation of reinforcing
phase within a metal matrix. The reinforcements can be formed from the precipitation in
liquid or solid. This method provides thermodynamic compatibility at the matrix-
reinforcement interface. The reinforcement surfaces are also likely to be free of
contamination and, therefore, a stronger matrix-dispersion bond can be achieved [9][14].
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III. METAL MATRIX COMPOSITES COMPARED WITH POLYMER MATRIX

COMPOSITES AND CERAMIC MATRIX COMPOSITES
The following table is a summary of the properties and processing methods used for
polymer-, metal-, and ceramic- matrix composites.

Polymer Matrix Metal Matrix Ceramic Matrix

Composites Composites Composites
Modulus Medium Very High Very High
Very High (tension) High (tension) Medium (tension)
Strength
High (compression) High (compression) High (compression)
Density Low Medium Medium
Creep High High Low
Resistance
Fracture High Medium Low (key criterion)
Toughness
Fatigue High Medium Low
- Sheet Molding * Solid State * Conventional Ceramic
- Injection Molding - Powder Metallurgy Consolidation
- Resin Transfer - Foil Diffusion Bonding - Cold-pressing and
Molding * Liquid State sintering
- Prepreg Tape Lay-up - Electro-plating/formin * Porous Pre-form
- Pultrusion - Stir Casting Infiltration
- Filament Winding - Pressure Infiltration - Polymer Infiltration
Fabrication
- Thermal Forming - Squeeze Casting and Pyrolysis (PIP)
Methods
- Spray Deposition - Reactive Liquid
- Reactive Processing Infiltration
* Semi-Solid State - Chemical Vapor
- Semi-solid powder Infiltration (CVI)
processing
* Vapor Deposition
- Physical Vapor
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Deposition
* In-situ Fabrication
Ease of Easy Difficult Medium
Fabrication
Cost Low Medium High
Current Extensively used Moderately used Rarely used
Status

Table 1 Summary of the properties and processing methods [2][3][4][5]

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IV. COMPARISON OF THE PROPERTIES OF ALUMINUM AND MAGNESIUM

METAL MATRIX COMPOSITES
1. Aluminum MMCs:

Table 2 is a summary of the properties of aluminum metal and aluminum MMCs

reinforced with particulates and fibers.

Properties Matrix Metal(1) Particulate Fiber

MMCs (2) MMCs(3)
Strength (MPa) (axial) 290 290-489 620-1240
Stiffness (GPa) (axial) 70 80-140 130-450
Transverse Strength (MPa) 290 290-480 30-170
Transverse Stiffness (GPa) 70 80-140 34-173
Plane strain fracture 18-35 12-35 ---
toughness (MPa-m)
Table 2 Properties of representative Aluminum MMCs [9]
(1) 6061 Aluminum
(2) 6061 Aluminum reinforced with 0-40% volume fractions of SiC particulate
(3) 6061 Aluminum reinforced with 50% volume fractions of fibers of graphite, B, SiC,
alumina

Table 3 shows the properties of aluminum MMCs reinforced with fiber (50% volume
fraction).
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Aluminum Tensile Tensile Stiffness Stiffness

MMCs Strength Strength (GPa) (axial) (GPa)
(50% fiber (MPa) (MPa) (transverse)
volume fraction) (axial) (transverse)
Graphite 690 30 450 34
Boron 1240 140 205 140
Silicon Carbide 1040 70 130 99
Alumina 620 170 205 140
Table 3 Properties of Fiber Reinforced Aluminum MMCs (fiber volume fraction 50%)
[9]

2. Magnesium MMCs:

Table 4 provides certain properties of magnesium MMCs at different content of

reinforcement.

Materials 0.2% Yield Specific Ultimate Tensile Specific Ductility

Strength Yield Strength Ultimate Tensile (%)
(MPa) Strength (MPa) Strength
Mg 100 58 258 148 7.7
Mg-2% Cu 281 148 335 177 2.5
Mg-4% Cu 355 170 386 184 1.5
Mg-7% Cu --- -- 433 195 1.0
Mg-2% Ni 337 177 370 194 4.8
Mg-3% Ni 420 203 463 224 1.4
Mg-6% Ni --- -- 313 131 0.7
Mg-2% Ti 163 90 248 127 11.1
Mg-4% Ti 154 81 239 126 9.5
Mg-30% SiC 229 105 258 118 2
(Particulate)
Table 4 Certain properties of magnesium MMCs [11]
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V. CURRENT STATUS OF METAL MATRIX COMPOSITES & FUTURE

DIRECTION

As ‘green’ technologies draw significant attention around the world, manufacturing

companies have utilized MMCs to produce lighter and efficient materials for fuel-efficiency
automobiles and aircrafts. The new developments in hybrid and electric vehicles as well as
power transmission cables have increasingly used aluminum MMCs for its light weight and
high strength [2][6][16].
Even though discontinuously reinforced MMCs are the most widely used, the difficulty
in fabrication has restrained its commercialization. Therefore, more processing methods with
less impact on the microstructural integrity of these materials are being researched. In
addition, many studies on aluminum MMCs have been conducted recently: improving
damage tolerance, manufacturing high-quality reinforcements from industrial wastes and by-
products, or developing aluminum MMCs based on non-standard aluminum alloys [9][16]. It
is estimated that in the next 15 years, new developments of MMCs in the automobile industry
will be applied to connecting rods, rocker arms, brake components, and pistons [7].
In addition, robot components, propeller shafts, electronic packaging, computer
equipment, and even sporting goods have been fabricated using MMCs [6]. However, the
high cost of manufacturing has hindered the wide applications and commercialization of
MMCs and narrowed its applications to mostly the production of mechanical components.
Recently, 3M has developed continuously reinforced aluminum MMCs for use in overhead
power transmission conductors [16]. This newly developed product can be utilized as high
tension wires and will significantly raise the demand for aluminum MMCs in the future.
Even though titanium is heavier, more expensive, and more difficult to machine than
aluminum, it retains properties at high temperature and thus its alloys are widely used in
devices or machines that require high temperature properties [16].
Another rapid development in MMCs is demonstrated in the use of metallic glasses.
Metallic glasses have high strength but low ductility in the bulk form. However, when
metallic glasses are used as reinforcements for metal matrix, they provide stronger
composites with significantly improved fracture properties. Recent investigations have been
conducted to utilize metallic glasses in MMCs with higher volume fraction to provide
stronger and tougher materials [16].
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VI. SUMMARY AND CONCLUSION

Metal matrix composites usually consists of light-weight metals like aluminum,

magnesium, or titanium, and the reinforcements are usually ceramic particulates, whiskers, or
fibers. The reinforcements are an important factor in determining the properties,
performance, or fabrication of the MMCs. Since there is a wide variety of types of
reinforcements and fabrication methods, the data for properties of different MMCs are
usually inconsistent. Generally, aluminum MMCs and magnesium MMCs have many
similarities in mechanical properties and are most widely used for light-weight components
in the automobile and aerospace industries. Titanium MMCs are used specifically for
applications that require high temperature properties. More research investigations and
development studies are being conducted to further enhance the properties and fabrication
technologies, promoting the application and commercialization of MMCs in the future.
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[12] Poletti, C., Balog, Schubert, Liedtke, and Edtmaier. 2008. Production of titanium matrix
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[13] Arvieu, C., Even, Guillaume, Bobet, Quenisset and Chadeyron. Processing of Carbon Fiber
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[16] Cyriac, A. 2011. Metal Matrix Composites: History, Status, Factors and Future. Graduate
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